Fuel cell



ticient and practical fuel cell.

United States Patent 3,252,837 FUEL CELL Charies N. Satterfield, South Lincoln, and John 0. Smith,

Swampscott, Mass., and Kenneth L. Mcliugh, Kirkwood, Mm, assignors, by mesne assignments, to Monsanto Research Corporation, Everett, Mass., 21 corporation of Delaware No Drawing. Filed May 8, 1961, Ser. No. 108,272

19 Claims. (Cl. 13686) This invention relates to fuel cells and provides a new and valuable means for the direct conversion of chemical energy into electrical energy.

In prior art, such production of electrical energy has been generally accomplished by the provision of cells wherein there is utilized the chemical energy produced by the reaction of hydrogen or a carbonaceous fuel with oxygen or air. Whereas such reactions could be effected at ordinary or moderately elevated temperatures when the fuel was hydrogen, in order to employ carbonaceous fuels such as carbon, coal or methane, it has been necessary to employ very high temperatures, i.e., those attainable through molten salt mixtures. Accordingly, the art .generally refers to hydrogen-oxygen cells as low temperature fuel cells and to the carbon-oxygen cells as high temperature fuel cells. The oxidizab-le component of a fuel cell is generally referred to as the fuel and the oxidizing component as the oxidant.

Numerous power applications, especially those of military nature, require high energy per unit weight power sources; and, in theory, the fuel cell is ideal for such applications. Since the weight of the fuel cell can be small compared to the weight of the fuel and oxidant,

and because the cell can operate at up to 100% thermodynamic efiiciency, fuel cells are a means by which the maximum theoretical energy-weight ratio of a chemical power source can be approached. There are. limitations, however, on the type of fuel cell that can be used as a convenient and compact power source. The high temperature cells, of course, are inconvenient for field purposes and the use of hydrogen as fuel and oxygen as the oxidant present problems of unwieldy storage and cumbersome transportation. Since the weight of high pressure vessels is large, a gaseous fuel-oxidant system which requires storage at high pressure cannot be considered as either convenient or compact. Also, whereas, in theory the use of air rather than of oxygen negates storage and transportation problems insofar as the oxidant is concerned, in practice, air is an ineflicient oxidant com-- ponent of fuel cells, at least with presently known electrodes, because nitrogen accumulates in electrode pores and thereby reduces the rate at which oxygen can be transported to the active interface, whereby the discharge of electrons atthe electrode is retarded and a marked decrease in power output results.

An object of the present invention is to provide an ef- Another object of the invention is to provide a fuel cell which operates at ambient temperatures and employs an easily stored and handled fuel. Still another object of the invention is to provide an efficent, low-temperature fuel cell which employs an easily stored and handled oxidant. A further object of the invention is to provide an economically feasible fuel cell employing, as fuel and oxidant, materials which are readily available, easily stored, and conveniently handled.

These and other objects which will be hereinafter disclosed are provided by the invention wherein there is provided a low temperature fuel cell that employs a lower alkanol as the fuel and an easily stored and handled oxidant.

3,252,837 Patented May 24, 1966 ice More particularly, the invention provides a fuel cell, operable at ambient temperature, and designed for the direct production of electrical energy from chemical energy by the reaction of a fuel and an oxidant therefor, said cell comprising a pair of spaced electrodes in contact with each other through an aqueous electrolyte, one of said electrodes being continuously maintained in contact with an alkanol of from 1 to 3 carbon atoms, while the other of said electrodes is being continuously maintained in contact with an oxidizing agent selected from the class consisting of hydrogen peroxide, reducible inorganic oxides and oxy acids, and the alkali metal and alkaline earth metal salts of said oxy acids. The invention thus provides also a method for conversion of chemical energy directly into electrical energy which comprises continuously introducing an alkanol of from 1 to 3 carbon atoms at one of said pair of electrodes while continuously introducing the oxidizing agent at the other of the pair of electrodes.

The presently useful alkanols include methanol, ethanol, propanol and isopropanol. Because presence of water of the feed may result in dilution of the electrolyte, it is advantageous to employ substantially anhydrous alkanol. However, a substantial quantity of water may be present in the alkanol feed. This will depend upon the conditemperatures, water may be an undesirable component of the feed since the freezing point of water-alkanol mixtures increases with increasing water content; whereas, at higher temperatures and with the less active oxidizing agents, mixtures of alkanol and water may be desirable. Dilution of the alkanol by water can be readily compensated for, of course, either by corresponding dilution of the oxidant, by varying the rate at which the oxidant and/or fuel is added, and by varying the potency of the oxidant insofar as available oxygen is concerned. Since such variations are matters of only routine determination, whether or not water may be present in the alkanol feed and the extent of optimum dilution, if any, can be readily arrived at by one skilled in the art.

When dilute aqueous solutions or dispersions of oxidizing agent are employed as the oxidant, it may be advantageous to add at the anode a solution of the alkanol in the aqueous electrolyte while withdrawing electrolyte solution from the cell chamber, Undue dilution of the electrolyte within the cell is thus prevented. When operating by using an electrolyte solution of the alkanol as the feed, say, a solution of methanol in aqueous sulfuric acid, current output is noted even at concentrations of alkanol which are low as 0.10 molar, although in this case, the rate of mass transfer becomes slow and there is a resulting lowering in electrode potential. It is thus desirable to use in the feed of the alkanol plus electrolyte, aqueous solutions of the alkanol which are at least 1.0 molar.

The optimum quantity of alkanol in an aqueous feed will be regulated, of course, to some extent, by other fuel cell factors, e.g., the nature and concentration of the electrolyte and of the material employed as the anode. These factors, of course, can be arrived at experimentally by one siklled in the art. Obviously, the rate at which input of the alkanol is conducted should correspond to the rate at which available oxygen is supplied by input of oxidant; and obviously, of course, the concentration of the electrolyte should be maintained at a value which maiiitains optimum ion transport. These factors can be determined by simply noting variation in the current output of the cell and by varying the concentration of fuel, oxidant and electrolyte accordingly.

The rate and concentration of oxidant input will vary, of course, with that of the fuel and be in proportion thereto stoichiometrically. Generally, the oxidation proceeds to completion, the products originating from, e.g., methanol, being carbon dioxide and water. At all but the lowest current densities, when acidic or neutral media are used, bubbles of carbon dioxide are evidenced at a rate that appears to be proportional to the current developed. In basic solutions the evolved carbon dioxide forms carbonates.

In the presently providedfuel cell, it is believed that electrical energy is provided by reaction of the alkanol at the anode to give intermediate oxidation products, positively charged hydrogen ions, and electrons which are provided to the load. The intermediate oxidation products progressively react'at the electrode to give more positively charged hydrogen ions and more electrons to the load until, as the final product of oxidation, carbon dioxide is formed.

The electrons travel through the load and arrive at the cathode while the aqueous oxidant is being added thereto in the presence of the electrolyte. Hydroxyl ions are thus formed. The total reaction, employing hydrogen peroxide as the oxidant and methanol as the reductant, is thus:

with the transfer of 6 electrons.

Inorganic reducible oxides or oxy acids or the alkali metal or alkaline earth metal salts of the oxy acids also lose oxygen at the cathode in presence of a non-acidic electrolyte to yield hydroxyl ions which combine with the hydrogen ions evolved from the alkanol at the anode. The term reducible oxides and oxy acids, as herein employed, means reducible compounds having one or more oxygen atoms, including peroxides, superoxides and peroxy acids. Examples of such presently useful compounds, in addition to hydrogen peroxide, are the oxy acids such as nitric, nitrous, sulfuric, persulfuric and perphosphoric acids; oxides, peroxides and superoxides such as NO, N 2 3 2 5 2 2$ 2, 2 3 N302, 2 2 2, 2, C302, CIOZ, CF03, V205, S02, S602, T602, T603, M002, M0205, M003, W02, W205, W03, Mn O M11203, M1102, M1103, M11205, M11207, Fe O C0203, Nl2O Nlaoi @lIC- The useful alkali metal or alkaline earth metal salts of the oxy acids are, e.g., sodium, potassium, lithium, rubidium, cesium, barium, calcium or magnesium chromates, di-

chromates, polychromates, persulfates, perphosphates, mo-' lybdates or dimolybdates or the hydrates of tetra-, octa-, or decamolybdates, tungstates or paratungstates or the hydrates thereof, manganates or' permanganates or the hydrates thereof, ferrites, ferromolybdates, ferrotungstates, etc. Aqueous solutions or dispersions of varying concentrations of the oxidizing agent in sufiicient quantity to supply the stoichiometrically required amount of oxygen, with respect to the fuel, are used.

Acidic, basic or neutral electrolytes commonly used in electrolytic processes are generally useful for the present purposes. There may be used, e.g., aqueous solutions of sodium, potassium, lithium, magnesium, or barium hydroxides and the chlorides thereof; potassium, sodium, or lithium sulfate or carbonate, or bicarbonate, sulfuric acid, p-toluenesulfonic acid, phosphoric acid, hydrochloric acid, etc. As is known to the art, the electrical conductivity of aqueous solutions generally is a function of the concentration of the electrolyte, the conductivity usually reaching a maximum at a certain concentration which may be different for each electrolyte. Accordingly, in order to maintain continuous, effective operation of the fuel cell, detrimental dilution of the electrolyte by water of reaction and/or any other products should be avoided by providing for their removal from the cell. The removal of water for the purpose of maintaining constant cell operation are matters of engineering expediency which have been resolved in known manner for other fuel cells whereplatinum, silver or in water is a by-product. For example, water may be removed by boiling, freezing, drying over alumina, etc., in order to reconcentrate the electrolyte. Gaseous waste products, if any, can be readily removed by venting; and insoluble products, e.g., precipitates of metal which may be formed by use, as oxidant, of the metal oxides or salts of the oxy acids of metals, are readily removable by filtering, settling or decanting.

The electrodes, which are spaced apart in the electrolyte, comprise a fuel electrode, which is herein referred to as an anode, and the oxidant electrode, herein referred to as the cathode. Both electrodes may be cylindrical or rectangular bars or plates of plain or porous structure which may be of carbon, pressed and molded metallic particles or powdered metals, e.g., nickel, platinum, silver, gold, cadmium, Raney nickel-aluminum alloy, magnesium, zinc or silicon. Advantageously, they may comprise a carrier skeleton, e.g., of carbon, sintered stainless steel, fritted glass, or metal gauze, having coated thereupon or imbedded therein, catalysts such as palladium, gold, iridium. The requirement that the cell be stable over long periods of time excludes, of course, electrode materials which are known to be attacked by the particular type of electrolyte in use. For example, since the chloride ion reacts with even those metals which are usually considered to be inert, chlorides are generally of little utility as electrolytes in fuel cells which employ metal electrodes. Chloride electrolytes may be used with inert materials such as carbon.

The electrodes may be conveniently hollowed for easy introduction of the fuel and oxidant into the cell. Thereby these components diifuse through the porous electrode structure to the electrode surface where reaction takes place. However, the fuel and the oxidant may also be mechanically impinged upon the electrode surface. Conveniently, also, the fuel and the oxidant may be dissolved in the aqueous electrolyte and the resulting solutions of electrolyte and reactant may be added at the respective electrodes while removing excess aqueous electrolyte from the cell. This expedient permits maintenance of the electrolyte at substantially constant concentrations in the cell while facilitating ion transport.

While he choice of electrode will depend to some extent upon the nature of the electrolyte and of the oxidant, we have found that generally the conventional carbon or nickel-aluminum alloy electrodes serve satisfactorily as either anodes or cathodes. While improvement in current output usually can be obtained by coating or impregnating such electrodes with catalysts known to promote oxidation and reduction reactions such as platinum, silver, palladium, etc., judicious choice of catalyst is again controlled by factors such as nature of electrolyte, oxidant, rate of feed, proportion of fuel to catalyst, etc., which factors can be arrived at by routine experimentation and are not controlling upon the present invention,

i.e., the production of electrical energy from the lower alkanols and an aqueous oxidant in the presence of an electrolyte.

The invention is further illustrated by, but not limited to, the following examples.

Example 1 This example shows a fuel cell wherein ethanol is employed as the fuel, nitric acid is used as oxidant, and platinum metal is used for both electrodes.

A fritted glass disc was inserted into the bottom of a U- shaped glass container in order to divide the tube into an anode compartment and a cathode compartment. The U-tube was then substantially filled with l M aqueous sulfuric acid to serve as electrolyte. Platinized platinum metal electrodes were used for both the anode and the cathode. These were respectively inserted into each leg of the tube so that they were almost completely immersed in the electrolyte. Concentrated nitric acid was continuously added, dropwise, at the cathode and ethanol was added simultaneously and in the same manner at the anode. Upon connecting the voltmeter directly across the electrodes, the cell was found to have an open circuit voltage of 0.75 volt. Upon connecting the ammeter directly across the two electrodes the short circuit current, or maximum current output of this cell was found to be 70 milliamperes.

Use of methanol or propanol instead of ethanol gives similarly good results.

Example 2 This example shows an ethanol-potassium permanganate fuel cell wherein there are employed carbon electrodes upon which platinum or silver had been deposited.

Each of the two 1" x 1" x 4" carbon electrodes had at its center a circular aperture, 0.5" in diameter, longitudinally disposed therein to within 0.5 of the end of the electrode. One longitudinal face of each electrode had a thin coating of either platinum or silver deposited thereon. With the open ends up, the electrodes were immersed at a spaced distance from each other and with the coated surfaces facing each other into a glass container containing 2 N aqueous sodium hydroxide as electrolyte. The silver-coated electrode served as anode and the platinum-coated electrode served as cathode. Ethanol was continuously introduced, dropwise, into the aperture of the anode, and 3% aqueous potassium permanganate was added simultaneously and in the same manner into the cathode. The resulting cell was found to have an open circuit voltage of 1.10 volts and a maximum current output of 2+ amperes, as determined by connecting a voltmeter or an ammeter directly across the electrodes.

Operating as above, but employing 1 M aqueous sulfuric acid as electrolyte, there was produced an open circuit voltage of 1.10 volts and a maximum current output of 1.5 amperes. Use of isopropanol, instead of ethanol, similarly provides a cell having an open circuit voltage of over 1 volt in either the acidic or basic electrolyte. Similarly good results are obtained 'by employing calcium permanganate, instead of potassium permanganate, with the ethanol or isopropanol.

Example 3 Example 4 This example describes a multiplate cell wherein ethanol is employed as a fuel with a liquid oxidant.

Thin sheets of carbon, 4" square and A3" thick upon each of which had been deposited 1% by weight of plati num are used as the electrodes. Three of these electrodes, destined to serve as anodes, are saturated with concentrated ethanol and three of them, destined to serve as cathodes, are saturated with concentrated niric acid. The anodes and cathodes are then alternately spaced on a rack so that they are A" apart. The entire assembly is then immersed in the electrolyte (2 M sodium hydroxide). The resulting cell operated a small, motor-driven flywheel.

Example 5 In this experiment, the electrodes described in Example 2 were used as anode and cathode, respectively. Hydrogen peroxide was used as oxidant. The two electrodes, with coated surfaces facing each other, were immersed in a glass container containing 5 N aqueous potassium hydroxide and ethanol was added to the silvercoated electrode while 30% aqueous hydrogen peroxide was simultaneously added to the platinum-coated electrode. There was thus obtained an open circuit voltage of 0.4 volt and a short circuit current or maximum current output of 30 milliamperes.

Operating as above, but employing 1 M sulfuric acid as electrolyte instead of the potassium hydroxide, there was obtained an open circuit voltage of 04 volt and a maximum current output of 20 milliamperes.

The above examples and data illustrate the efiiciency of the lower alkanOls as fuels in a cell employing aqueous oxidant material and an electrolyte. Instead of employing the substantially pure alkanols, aqueous solutions thereof may be used, and the nature of the oxidant and of the electrolyte and electrodes may be widely varied, as hereinbefore disclosed.

The presently provided fuel cells operate at all temperatures, between the boiling point of the electrolyte on the one hand, and the freezing points of the electrolyte and of the feed on the other. Between these limits, the short-term behavior of the cell improves noticeably with increasing temperature. In the region of the boiling point, however, performance declines significantly as a result of formation of vapor bubbles on the electrode surface. Generally, neither external heating nor cooling will be required, but the entire cell may be cooled or warmed, if desired, by a jacket containing a coolant or a heat-transfer medium, and both the anode and cathode may be equipped with condensers. However, operation of the cell generally results in no substantial temperature increase.

Stirring of the electrolyte, during cell operation may be advantageous if heat dissipation is advisable; frequently, stirring of the electrolyte will facilitate ion transfer. cal or magnetic means.

Specific process conditions of cell operation will vary, of course, with different cell structures, with surface area of electrodes, as well as with the other variables already mentioned. The details of cell housing, electrode structure, etc., are not critical in carrying out operation of the cell, and the cell may be altered in numerous ways, so long as there is employed the alkanol feed, the aqueous oxidant and the electrolyte. Also, any number of cells can be combined into a single unit The production of electrical energy can be carried out continuously, e.g., by means of a circulating pump, whereby the electrolyte is withdrawn from the cell for revivification if desired by separating reaction products therefrom, and the revivified electrolyte is reintroduced into the cell continuously, together with the feed, or separately.

With some electrolytes and with some oxidants it may be advantageous to divide the cell into a cathode compartment and an anode compartment. This may be done by means of a diaphragm which may be a porous, porcelain structure of a permeable membrane. An ionexchange resinous material may serve as such membrane, and the nature of the electrolyte adjusted accordingly.

Use of liquid fuel and liquid oxidant permits substantially more simple cell construction than is required for cells employing gaseous feed and at the same time provides a highly efficient means of converting chemical energy into electrical energy. While the invention has been described herein in detail with reference to the specific embodiments shown and the alternatives thereto, various other changes and modifications will become apparent to the artisan which fall within the spirit of the invention and the scope of the following claims.

What we claim is: i

1. A fuel cell comprising a pair of spaced inert electrodes in electrical contact with each other through an undivided aqueous electrolyte, one of said electrodes being continuously maintained in cont-act with a liquid alkanol of from 1 to 3 carbon atoms as fuel, while the other of Stirring, if desired, may be conducted by mechanisaid electrodes is continuously maintained in contact with an aqueous oxidizing agent selected from the class consisting of hydrogen peroxide, reducible inorganic oxides and oxy acids, and the alkali metal and alkaline earth metal salts of said oxy acids, said aqueous oxidizing agent being supplied to said electrode by introduction thereof at the electrode.

2. The fuel cell defined in claim 1, further limited in that the fuel is ethanol.

. 3. The fuel cell defined in claim 1, further limited in that the fuel is methanol.

4. The fuel cell defined in claim 1, further limited in that the fuel is isopr-opanol.

5. The fuel cell defined in claim 1, further limited in that the fuel is n-propanol.

6. The fuel cell defined in claim 1, further limited in that the fuel is ethanol and the oxidizing agent is nitric acid.

7. The fuel cell defined in claim 1, further limited in that the fuel is ethanol and the oxidizing agent is potassium permanganate.

8. The fuel cell defined in claim 1, further defined in that the fuel is ethanol and the oxidizing agent is calcium permanganate.

9. The fuel cell defined in claim 1, further defined in that the fuel is ethanol and the oxidizing agent is hydrogen peroxide.

10. The process for conversion of chemical energy directly into electrical energy which comprises continuously introducing a liquid alkanol of 1 to 3 carbon atoms as fuel at one of a pair of spaced inert electrodes, which electrodes are in electrical contact with each other through an undivided aqueous electrolyte, while continuously introducing at the other of said pair of electrodes an aqueous oxidizing agent selected from the class consisting of hydrogen peroxide, reducible inorganic oxides and oxy acids, and the alkaline metal and alkaline earth metal salts of said oxy acids. 7

11. The process defined in claim 10, further limited in that the fuel is ethanol.

12. The process of claim 10, further limited in that the fuel is methanol.

13. The process of claim 10, further limited in that the fuel is ispropanol.

14. The process of claim 10, further limited in that the fuel is n-propanol.

15. The process of claim 10, further limited in that the fuel is ethanol and the oxidizing agent is nitric acid.

16. The process of claim 10, further limited in that the fuel is ethanol and the oxidizing agent is potassium permanganate.

17. The process of claim 10, further limited in that the fuel is ethanol and the oxidizing agent is calcium permanganate.

18. The process of claim 10, further limited in that the fuel is ethanol and the oxidizing agent is hydrogen peroxide.

19. The process of claim 10, further limited in that the fuel is methanol and the oxidizing agent is an aqueous solution of chromium trioxide.

References Cited by the Examiner UNITED STATES PATENTS 311,853 2/1885 Roberts 136-137 870,985 11/1907 Mollenbruck 136l36.6 1,039,949 10/1912 Jaeger 136136.6 2,233,593 3/1941 Eddy et al 136136.6 2,384,463 9/1945 Gunn et al. 136-86 2,667,405 1/1954 Muller 136138 2,706,213 4/1955 Lucas 136137 2,830,109 4/1958 Justi et a1. 136-86 2,925,454 2/1960 Justi 13686 2,991,325 7/1961 Kordesch 136-138 FOREIGN PATENTS 625,183 8/1961 Canada. 441,327 1/1936 Great Britain.

WINSTON A. DOUGLAS, Primary Examiner.

JOHN R. SPECK, JOHN H. MACK, Examiners. 

1. A FUEL CELL COMPRISING A PAIR OF SPACED INERT ELECTRODES IN ELECTRICAL CONTACT WITH EACH OTHER THROUGH AN UNDIVIDED AQUEOUS ELECTROLYTE, ONE OF SAID ELECTRODES BEING CONTINUOUSLY MAINTAINED IN CONTACT WITH A LIQUID ALKANOL OF FROM 1 TO 3 CARBON ATOMS AS FUEL, WHILE THE OTHER OF SAID ELECTRODES IS CONTINUOUSLY MAINTAINED IN CONTACT WITH AN AQUEOUS OXIDIZING AGENT SELECTED FROM THE CLASS CONSISTING OF HYDROGEN PEROXIDE, REDUCIBLE INORGANIC OXIDES AND OXY ACIDS, AND THE ALKALI METAL AND ALKALINE EARTH METAL SALTS OF SAID OXY ACIDS, SAID AQUEOUS OXIDIZING AGENT BEING SUPPLIED TO SAID ELECTRODE BY INTRODUCTION THEREOF AT THE ELECTRODE. 